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Escort RS2000 4x4 2.0 Turbo Conversion

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blacksofstichill Community Regular

blacksofstichill

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Yes, you can definitely cause problems if you grind the valves back too much to reface them, the most common problem is that the edge of the valve becomes too sharp and it leads to the valve being burned at this point, it would have to be very badly pitted for this to happen though and it would be a case of renewing the valves at that stage.

 

The tappets or valve lifters follow the profile of the camshafts and in turn this allows them to push the valves open or allow the valves to close. Hydraulic tappets (as opposed to mechanical/solid lifters) use oil pressure to maintain zero valve clearance so they never need any adjustment. :cheers:

 

The replacement head, like the original one had dulled quite a bit and had some surface corrosion to the outer surface which is purely cosmetic but in the interests of making the engine look it's best I masked it up ready for painting -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0309.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0310.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0311.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0312.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0313.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0314.jpg

 

I Painted it with Simoniz Silver Engine Enamel, I've used it before and it seems to work well -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0315.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0316.jpg

 

Masking Tape removed -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0317.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0318.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0319.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0320.jpg

 

I laid it onto the block for the paint to dry and also to see how it looked -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0321.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0322.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0323.jpg

 

With the paint set on the Cylinder Head I removed it from the block to fit it properly -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0324.jpg

 

Delving into the box of tricks Olly sent up we have a Genuine Ford Multi Layer Steel Head Gasket -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0325.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0326.jpg

 

Gasket laid in place and one last look at the fresh bores and those cracking pistons -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0327.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0328.jpg

 

Cylinder Head Laid into place -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0329.jpg

 

New Cylinder Head Bolts -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0330.jpg

 

Head Torqued down -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0331.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0332.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0333.jpg

 

The original Bolts for the Cam Sprockets and the Chain Guides had long since seen better days, the heads were all chewed up and the threads had been loctited -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0334.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0335.jpg

 

So, into my stock of spares and I replaced them with good ones -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0336.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0337.jpg

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blacksofstichill
blacksofstichill

Yeah, we have a new rad for the job, the old one is just for the trial fitment.     Cheers!  I do have a bad memory but I hadn't forgotten about you!     Cheers!     Thanks, I should maybe have built

ganges
ganges

here we go again......yet another great start, to another great thread

blacksofstichill
blacksofstichill

Onto the Transfer Box now, here it is as removed from the car - http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01532.jpg http://blackengineering.co.uk/images/Doctor-Evi

blacksofstichill Community Regular

blacksofstichill

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Cheers! Here's some more for you.....New Timing Chain kit -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0338.jpg

 

The AE Timing Chain is top quality but as you'll see it has no coloured links to line up the timing marks with -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0339.jpg

 

So, after laying it out alongside the Rolon one I painted my own markings on the correct links, although the coloured links aren't essential they do provide a good double check -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0340.jpg

 

Original Timing Chain guide was mint, it must have been replaced during the last rebuild as there was no sign of any wear on it at all -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0341.jpg

 

Chain Fitted to the crank sprocket -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0342.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0343.jpg

 

New Tensioner plunger -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0344.jpg

 

Fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0345.jpg

 

New Tensioner Sprocket ready to fit -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0346.jpg

 

Fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0347.jpg

 

Cams ready to fit -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0348.jpg

 

Inlet Cam is standard RS profile -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0349.jpg

 

Exhaust Cam is a custom Regrind by Kent Cams -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0350.jpg

 

At the top of my thumbnail on this photo you can see where the new grind meets the old one on the chamfer -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0351.jpg

 

Kent Cams stamping on the casting -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0352.jpg

 

Lift of the Exhaust Cam is reduced from Standard -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0353.jpg

 

Cams Laid in place -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0354.jpg

 

Cam Bearing Cap Studs fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0355.jpg

 

Cam Bearing Caps fitted and torqued down -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0356.jpg

 

Sprockets fitted and Cams Timed up -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0357.jpg

 

New Chain Guide -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0358.jpg

 

Fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0359.jpg

 

Tensioner Plunger releases to take up the slack and that's it all timed up -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0360.jpg

 

Upper Timing Cover ready for a clean up -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0361.jpg

 

Cleaned up ready to paint -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0362.jpg

 

And painted with Silver Engine Enamel to match the head -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0363.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0364.jpg

 

Lower timing cover as removed from the engine -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0365.jpg

 

Old Oil Seal removed and New one ready to fit -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0366.jpg

 

 

New Oil Seal fitted and cover cleaned up ready to fit -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0367.jpg

 

Also, here are a few Tech Specs for this engine from the measurements I took and calculations I made before I built it all up -

 

Bore - 86.5mm (0.5mm overbore)

Stroke - 86.0mm (standard RS)

Capacity - 2022cc

Compression Ratio - 7.36:1

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blacksofstichill Community Regular

blacksofstichill

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Crankshaft Oil seal and housing as removed from the engine -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0368.jpg

 

Old Oil Seal removed on the left, new one ready to fit on the right -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0369.jpg

 

New Oil Seal fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0370.jpg

 

New gasket ready to fit -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0371.jpg

 

Gasket fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0372.jpg

 

And fitted to the engine -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0373.jpg

 

Moving on to the exhaust manifold, we decided to use the one that was already fitted to the engine rather than have a 200SX based one made up. The fact this manifold had already been fitted and worked was part of the reason but it also keeps the cost down on the overall project and will avoid clearance issues with the radiator, etc as this manifold tucks tightly into the block -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0374.jpg

 

The only thing against this manifold that neither Olly or me liked was the Welding on it. It was a solid enough job and Stevie Wonder may have been delighted with how it looked but we weren't -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0375.jpg

 

Masses of big ugly welds weren't doing it a lot of favours -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0376.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0377.jpg

 

On the plus side, the inside of the manfiold had been well matched to the RS2000 flange after all that welding -

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0378.jpg

 

So, to improve its looks I started dressing down the welds and grinding off casting marks and casting numbers, ect -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0379.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0380.jpg

 

It still looks a bit rough at this point but bear with me -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0381.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0382.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0383.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0384.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0385.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0386.jpg

 

Then I spent some timg going over it all with a flap wheel on the grinder to smooth it a bit further -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0387.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0388.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0389.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0390.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0391.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0392.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0393.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0394.jpg

 

With it looking a lot smoother and cleaner now I coated it with a high temp black and lacquered it -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0395.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0396.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0397.jpg

 

I know it won't stay as glossy as that for long once it's had some heat through it but it looks as best as it can for now

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blacksofstichill Community Regular

blacksofstichill

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Thanks, it took a bit of time but it was worth it when you see the difference it made. :cheers:

 

I popped it onto a couple of exhaust studs to see how it looked although it all maybe looks a bit "black" against the engine block there'll be a breather pipe running behind it which I'll paint in Silver to add some contrast and once the Turbo is bolted back onto it that'll break it up a bit -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0398.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0399.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0400.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0401.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0402.jpg

 

Next I decided to have a better look at the fuel rail, here it is as removed from the engine -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0403.jpg

 

As you can see, it has top feed injectors fitted into the standard inlet and using a steel fuel rail which has become quite rusty -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0404.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0405.jpg

 

Non-standard Weber Fuel Pressure Regulator -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0406.jpg

 

One-way valve on the breather pipe to prevent boost pressure from entering the inlet manifold -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0407.jpg

 

Fuel Rail and injectors removed from the Inlet -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0408.jpg

 

As can be seen from the photos, the injectors have been fitted into the inlet by using parts of the original fuel rail cut to suit, quite clever really, does the job very well -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0409.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0410.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0411.jpg

 

Injectors all removed from the Fuel Rail -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0412.jpg

 

 

Fuel rail all cleaned back to good metal -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0413.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0414.jpg

 

Primed -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0415.jpg

 

Painted in Satin Black -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0416.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0417.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0418.jpg

 

The inlet manifold itself is in need of a really good clean up before being painted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0419.jpg

 

Luckily, I was saved from cleaning the inlet that day when Olly had a load of Goodies for the engine delivered to me -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0420.jpg

 

Brand new Oil Pump -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0421.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0422.jpg

 

It might be a new pump but I'm still taking no chances with the Pressure Relief Valve screw coming slack, so I removed it -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0423.jpg

 

A few Dabs of loctite on the threads -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0424.jpg

 

And refitted it -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0425.jpg

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lee grout Veteran

lee grout

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I love this stage, when things get tarted up and its all coming together now :thumb: From the last pic before paint to the finished article, how much grinding/smoothing did you do....time wise? from the early grinds it looks a bit angular and the finished product looks rounded and smooth as a baby's bum.

 

 

 

 

 

 

P.S great job.....as if you needed reminding :rolleyes:

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blacksofstichill Community Regular

blacksofstichill

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I love this stage, when things get tarted up and its all coming together now :thumb: From the last pic before paint to the finished article, how much grinding/smoothing did you do....time wise? from the early grinds it looks a bit angular and the finished product looks rounded and smooth as a baby's bum.

 

 

 

 

 

 

P.S great job.....as if you needed reminding :rolleyes:

 

Cheers! :cheers: I think I had around 2 hours work on that manifold from start to finish, made all the difference to how it looks though so well worth it.

 

Oil Pump fitted to the Engine -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0426.jpg

 

New Oil Pump Chain ready to be fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0427.jpg

 

And fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0428.jpg

 

New Oil Pump Tensioner Pad, check out the wear on the old one -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0429.jpg

 

Tensioner Fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0430.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0431.jpg

 

Bottom Timing Cover ready to fit -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0432.jpg

 

Fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0433.jpg

 

Another one of Olly's purchases was this Bottom Pulley which was in better condition than our existing one -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0434.jpg

 

There were a few bits of rust starting to come back through on it though -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0435.jpg

 

So, I rubbed it down -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0436.jpg

 

Primed it -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0437.jpg

 

And Painted it in Satin Black -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0438.jpg

 

Bottom Pulley fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0439.jpg

 

Upper Timing Cover ready to fit along with Gasket whcih was also from Olly's latest delivery -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0440.jpg

 

Upper Timing Cover fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0441.jpg

 

It's taking shape now -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0442.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0443.jpg

 

Another excellent purchase by Olly, a New Water Pump -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0444.jpg

 

Just to help it look good for longer, I coated it with Silver Engine Enamel -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0445.jpg

 

New O-ring fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0446.jpg

 

Another item from the big box of tricks, powder coated Water Pump Pulley -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0447.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0448.jpg

 

Water Pump fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0449.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0450.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0451.jpg

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blacksofstichill Community Regular

blacksofstichill

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if you dont mind me asking, what sort of price would you charge for this kind of conversion?

 

It's hard to put a total price on it as my part of the job is pretty much labour only with the customer supplying the parts and the parts are often the most expensive element. The bare engine though built up to pretty much the stage you see it at just now would be around £600 plus VAT in labour. That leaves it at the stage where manifolds and all the other external elements are ready to be fitted. As you see this project progress though you'll see that I've had to do quite a lot of other work so the overall cost is considerably higher than just the bare engine itself. If someone was doing the rest of the work themself after the engine stage though you could keep the costs down. :cheers:

 

 

Really coming together now!

 

Cheers! :cheers:

 

Next up to sort out was the sump -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0452.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0453.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0454.jpg

 

After a bit of cleaning and degreasing it looked like this -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0455.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0456.jpg

 

After a light rub down I coated it in Silver Engine Enamel -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0457.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0458.jpg

 

New Sump Gasket fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0459.jpg

 

Sump fitted to the engine -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0460.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0461.jpg

 

Sump Plug with New Washer -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0462.jpg

 

Fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0463.jpg

 

Engine turned over again -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0464.jpg

 

Into the box of tricks again, this time for a new metal Exhaust Gasket -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0465.jpg

 

Exhaust Studs fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0466.jpg

 

Gasket fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0467.jpg

 

Manifold fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0468.jpg

 

Space is very tight to get the nuts onto a couple of the studs but other than that it fits perfect -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0469.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0470.jpg

 

Moving onto the Cam Cover now, the original one had been badly painted in Red -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0471.jpg

 

So, rather than spend ages cleaning the paint off, I swapped it for another one I had in stock, the Red one can always be blasted and coated at some point rather than trying to clean all that paint off by hand -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0472.jpg

 

And after being degreased it came up well -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0473.jpg

 

Masked off for painting -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0474.jpg

 

Primed -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0475.jpg

 

And Pinted in Satin Black, it's still wet at this point, hence the glossiness -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0476.jpg

 

Laid onto the engine for the paint to cure -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0477.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0478.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0479.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0480.jpg

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blacksofstichill Community Regular

blacksofstichill

Posted
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Cam Cover gasket fitted, the old ones were re-used as they were in good order and the new ones in the gasket set aren't a good fit at all -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0481.jpg

 

Cam Cover laid onto the Head -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0482.jpg

 

Into my stockpile and out came some Stainless Bolts and Nuts -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0483.jpg

 

Fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0484.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0485.jpg

 

Cam sensor from the Box of tricks ready to fit -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0486.jpg

 

And fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0487.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0488.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0489.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0490.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0491.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0492.jpg

 

Crank Sensor supplied by Olly, this one is correct as it's for a Mk6, the one from the original block was a Mk5 one and no good for this new engine -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0493.jpg

 

And fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0494.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0495.jpg

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blacksofstichill Community Regular

blacksofstichill

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Cheers! I'll have some pics up of the car itself later in the thread, there has been a lot of work done to it too so there are loads of updates still to come!

 

Here is the Turbo as removed from the engine and sent back down to the Owner who was getting it refurbished locally -

 

http://i579.photobucket.com/albums/ss237/doctorevil72/IMG_3907_zpsaf77f624.jpg

 

 

http://i579.photobucket.com/albums/ss237/doctorevil72/IMG_3908_zps1ae3b4bf.jpg

 

He was reccomended to take it to local specialists - CR Turbos in New Milton for a diagnosis

 

http://i579.photobucket.com/albums/ss237/doctorevil72/IMG_3920_zps95355d29.jpg

 

He said it is a T34 compressor from an Escort Cosworth mated to a Saph 4x4 turbine housing with a .46 a/r and a 270 degree bearing. He said it would be good for p 350bhp + once refurbed wityh a 360 degree bearing.

 

This is the last shot of the turbo on their reception counter next to some of their demonstartion cutaway models

 

http://i579.photobucket.com/albums/ss237/doctorevil72/IMG_3921_zpsc908194f.jpg

 

Olly had sent up a Thermostat Housing in good order, some of the sensors may be changed depending on what management is used but we'll cross that bridge when we come to it -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0496.jpg

 

New O-ring fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0497.jpg

 

Fitted to the head -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0498.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0499.jpg

 

Another great item in the spares box, a powdercoated bracket to mount the Alternator and Power Steering pump, it also had a good tensioner with a powdercoated pulley -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0500.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0501.jpg

 

Fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0502.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0503.jpg

 

Engine Mount Bracket, also powder coated -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0504.jpg

 

Fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0505.jpg

 

Here is the Crank Vent Piping as removed, it had already been modified to clear the exhaust manifold -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0506.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0507.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0508.jpg

 

All cleaned to bare metal -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0509.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0510.jpg

 

And painted in Silver Engine Enamel -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0511.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0512.jpg

 

Fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0513.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0514.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0515.jpg

 

Next I moved onto the plenum which was in a sorry state -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0516.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0517.jpg

 

Throttle Body removed -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0518.jpg

 

And here is what we are going to fit, an Escort Cosworth small turbo Throttle Body with an integrated Idle Control Valve -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0519.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0520.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0521.jpg

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